Genie S-40 Service Manual
  1. Manuals
  2. Brands
  3. Genie Manuals
  4. Lifting Systems
  5. S-40 TRAX
  6. Service manual

Genie S-40 Service Manual

Hide thumbs Also See for S-40:
Table of Contents

Advertisement

Quick Links

See also: Service & Repair Manual , Service Manual
Service Manual
Part No. 102521
Rev A
January 2005
Refer to inside cover for serial number information

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the S-40 and is the answer not in the manual?

Questions and answers

Related Manuals for Genie S-40

Summary of Contents for Genie S-40

  • Page 1 Service Manual Part No. 102521 Rev A January 2005 Refer to inside cover for serial number information...

  • Page 2: Introduction

    Important Serial Number Information Read, understand and obey the safety rules and Genie Industries offers the following Service operating instructions in the Genie S-40 and S-45 Manuals for these models: Operator's Manual before attempting any maintenance or repair procedure. Title Part No.
  • Page 3 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-40 and S-45 Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 4 Be sure that your workshop or work area hazardous situation which, if not is properly ventilated and well lit. avoided, may result in property damage. Green—used to indicate operation or maintenance information. Genie S-40 and S-45 Part No. 102521...

  • Page 5: Table Of Contents

    Perform Engine Maintenance - Deutz Models ..........3 - 8 Perform Engine Maintenance - Ford Models ..........3 - 8 Perform Engine Maintenance - Perkins Models ........... 3 - 9 Drain the Fuel Filter/Water Separator - Diesel Models ......... 3 - 9 Part No. 102521 Genie S-40 and S-45...
  • Page 6 B-13 Test the Drive Speed - Stowed Position ............ 3 - 27 B-14 Test the Drive Speed - Raised or Extended Position ......... 3 - 27 B-15 Perform Hydraulic Oil Analysis ..............3 - 28 B-16 Replace Hydraulic Filters ................3 - 28 Genie S-40 and S-45 Part No. 102521...
  • Page 7 Checklist E Procedures Test or Replace the Hydraulic Oil .............. 3 - 47 Perform Engine Maintenance - Deutz Models ..........3 - 49 Perform Engine Maintenance - Deutz Models ..........3 - 49 Part No. 102521 Genie S-40 and S-45...
  • Page 8 RPM Adjustment - Perkins Models ............4 - 18 Flex Plate ....................4 - 18 Engine Fault Codes - Ford Models ............4 - 20 Hydraulic Pumps Function Pump ..................4 - 21 Drive Pump ....................4 - 22 Genie S-40 and S-45 Part No. 102521 viii...
  • Page 9 7-13 Valve Adjustments, 4WD Traction Manifold ..........4 - 42 7-14 Valve Coils ....................4 - 43 Turntable Rotation Components Turntable Rotation Assembly ..............4 - 45 Axle Components Oscillate Axle Cylinders ................4 - 47 Part No. 102521 Genie S-40 and S-45...
  • Page 10 Hydraulic Schematic, 2WD Non-oscillating S-45 Models (before serial no. 7569) ................6 - 20 Hydraulic Schematic, 2WD Oscillating S-40 Models (before serial no. 7569) ..6 - 21 Hydraulic Schematic, 2WD Oscillating S-45 Models (before serial no. 7569) ..6 - 22 Electrical Schematic, Deutz F3L 2011 Models (after serial no.
  • Page 11 Ford LRG-425 EFI Models (after serial no. 7596) ........6 - 36 Hydraulic Schematic, 2WD (after serial no. 7568) ..........6 - 38 Hydraulic Schematic, 4WD (after serial no. 7568) ..........6 - 39 Part No. 102521 Genie S-40 and S-45...
  • Page 12 January 2005 This page intentionally left blank. Genie S-40 and S-45 Part No. 102521...

  • Page 13: Machine Specifications

    Turntable rotation 8 fl oz drive hub 0.24 liters Continuous improvement of our products is a Genie policy. Product specifications are subject to change Continuous improvement of our products is a Genie without notice. policy. Product specifications are subject to change without notice.

  • Page 14: Hydraulic Specifications

    40 ft/7.8 sec Chevron Rykon MV oil is fully compatible and 12.2 m/6.8 sec 12.2 m/7.8 sec mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are Drive speed, stowed 3.5 mph 3 mph designed to give maximum protection to hydraulic Deutz Diesel models 5.6 km/h...
  • Page 15 1.52 cu in 25 cc 4.3 cc Non-steer end drive motors Displacement - 2500 rpm 2.8 gallons per minute 10.6 liters per minute Displacement per revolution 2.13 cu in 35 cc Part No. 102521 Genie S-40 and S-45 2 - 3...

  • Page 16: Manifold Component Specifications

    68 Nm Drive motor mounting bolts, lubricated 38 ft-lbs 52 Nm Turntable bearing Turntable bearing mounting bolts, dry 220 ft-lbs 298 Nm Turntable bearing mounting bolts, lubricated 170 ft-lbs 230 Nm 2 - 4 Genie S-40 and S-45 Part No. 102521...

  • Page 17: A Ford Lrg-425 Efi Engine Specifications

    10.9 liters 20°F / -6.6°C Alternator Use oils meeting API classification SG (labeled SG/CC or SG/CD) as they offer improved wear protection. Output 95A, 14.5V DC Units ship with 10W-40 SG/CC. Part No. 102521 Genie S-40 and S-45 2 - 5...

  • Page 18: A Deutz F3L-1011F Engine Specifications

    -10°F to 90°F / -23°C to 32°C 10W-40 Temperature above -4°F / -34°C 15W-40 Engine oil should have properties of API classification SG/CC or CD/SG grades. Units ship with 10W-40 SG/CC. 2 - 6 Genie S-40 and S-45 Part No. 102521...

  • Page 19: A Deutz F4L-1011F Engine Specifications

    Temperature below 60°F / 15.5°C (synthetic) 5W-30 -10°F to 90°F / -23°C to 32°C 10W-40 Temperature above -4°F / -34°C 15W-40 Engine oil should have properties of API classification CC/SE, CD/SE, CC/SF or CD/SF grades. Part No. 102521 Genie S-40 and S-45 2 - 7...

  • Page 20: A Deutz F3L-2011 Engine Specifications

    Above 23° F / -5° C 20W-50 Fan belt deflection inch Engine oil should have minimum properties of API 9 to 12 mm classification CC/SG or CD/SG grades. Units ship with 10W-40 CH-4 2 - 8 Genie S-40 and S-45 Part No. 102521...

  • Page 21: A Perkins 704-30 Engine Specifications

    Engine oil should have properties of API classification CC/SE. API classification CD/SE or CCMC D4 can be used, but is not recommended during the first 50 hours nor for light load applications. Part No. 102521 Genie S-40 and S-45 2 - 9...

  • Page 22: A Perkins 404-22 Engine Specifications

    55A @ 12V DC 0.2 mm Fan belt deflection 10 mm Starter motor Current draw, no load Brush length, new 0.7480 in 19 mm Brush length, minimum 0.5 in 12.7 mm 2 - 10 Genie S-40 and S-45 Part No. 102521...
  • Page 23 12V, Group 31 Quantity Cold cranking ampere 930A Reserve capacity @ 25A rate 175 minutes Coolant temperature sending unit Torque 8-18 ft-lbs 11-24 Nm Temperature switch point 221° F 105° C Part No. 102521 Genie S-40 and S-45 2 - 11...

  • Page 24: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok ® The O-ring cannot be re-used if the fitting or fittings and hose ends. Genie specifications require hose end has been tightened beyond finger that fittings and hose ends be torqued to tight.
  • Page 25 Indicates that a specific result is expected after · Turntable secured with the turntable performing a series of steps. rotation lock · Key switch in the off position with the key removed · Wheels chocked Part No. 102521 Genie S-40 and Genie S-45 3 - 1...
  • Page 26 The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 27: Pre-Delivery Preparation

    PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Part No. 102521 Genie S-40 and Genie S-45 3 - 3 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev A...
  • Page 28 Section 3 • Scheduled Maintenance Procedures January 2005 This page intentionally left blank. 3 - 4 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 29: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 102521 Genie S-40 and Genie S-45 3 - 5...
  • Page 30 D-6 Engine maintenance - Legend Deutz models Y = yes, acceptable D-7 Calibrate platform N = no, remove from service overload system (if equipped) R = repaired D-8 Hydraulic filters Comments 3 - 6 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 31: Checklist A Procedures

    The Pre-operation Inspection also Complete information to perform this procedure is serves to determine if routine maintenance available in the Genie S-40 and S-45 Operator's procedures are required. Manual. Refer to the Operator's Manual on your machine.

  • Page 32: Perform Engine Maintenance - Deutz Models

    Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 3 - 8 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 33: Perform Engine Maintenance - Perkins Models

    Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. Part No. 102521 Genie S-40 and Genie S-45 3 - 9...

  • Page 34: Check For Fuel Leaks

    Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 3 - 10 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 35: Check The High Pressure Hydraulic Filter Condition Indicator

    See D-8, Replace the Hydraulic contact with the ground. Filters. If the chassis does not remain level during test, see Repair Procedure 7-6, How to Set Up the Oscillate Directional Valve. Part No. 102521 Genie S-40 and Genie S-45 3 - 11...

  • Page 36: Perform 30 Day Service

    Check the Oil Level in the Drive Hubs • B-17 Replace the Hydraulic Filters • C-1 Perform Engine Maintenance - Deutz Models • D-2 Check the Turnable Rotation Bearing Bolts 3 - 12 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 37: Perform Engine Maintenance - Ford And Perkins Models

    2 Inspect the filter bowl for water buildup. Result: If water is present in the filter bowl continue with steps 3 through 7. Part No. 102521 Genie S-40 and Genie S-45 3 - 13...
  • Page 38 See B-21, Replace The Fuel Filter Element - Perkins Models, for instructions on how to prime the fuel filter/water separator. 6 Clean up any fuel that may have spilled. 3 - 14 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 39: Check And Adjust The Engine Rpm - Perkins Models

    Crushing hazard. Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury. Part No. 102521 Genie S-40 and Genie S-45 3 - 15...

  • Page 40: Grease The Turntable Rotation Bearing And Rotate Gear

    Result: High idle should be 2200 rpm. (before serial no. 7472) Result: High idle should be 2500 rpm. (after serial no. 7471) If high idle rpm is correct, disregard adjustment step 4. 3 - 16 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 41: Perform Engine Maintenance - Ford Models

    January 2005 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A-17 Perform Engine Maintenance - Ford Models Part No. 102521 Genie S-40 and Genie S-45 3 - 17...

  • Page 42: Checklist B Procedures

    2 Be sure that the battery cable connections are free of corrosion. Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 3 - 18 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 43: Inspect The Electrical Wiring

    3 Inspect the following areas for burnt, chafed, result in death or serious injury. corroded and loose wires: · Engine wiring harness · Hydraulic manifold wiring Part No. 102521 Genie S-40 and Genie S-45 3 - 19...

  • Page 44: Perform Engine Maintenance - Deutz 1011F Models

    Crushing hazard. Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury. 3 - 20 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 45: Check The Oil Cooler And Cooling Fins - Deutz Models

    Crushing hazard. Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury. Part No. 102521 Genie S-40 and Genie S-45 3 - 21...

  • Page 46: Inspect The Tire And Wheels (Including Lug Nut Torque)

    3 Check each lug nut for proper torque. Refer to Section 2, Specifications . Models with air-filled tires: 4 Check pressure in each air-filled tire. Add air as necessary. Refer to Section 2, Specifications . 3 - 22 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 47: Check The Oil Level In The Drive Hubs

    Skip to step 5 if the low idle rpm is correct. Specifications . 4 Apply pipe thread sealant to the plug(s), and then install the plug(s) in the drive hub. 5 Repeat this procedure for each drive hub. Part No. 102521 Genie S-40 and Genie S-45 3 - 23...
  • Page 48 Result: Deutz F3L 1011F Engine High idle should be 2300 rpm. Deutz F4L 1011F Engine High idle should be 2200 rpm. Deutz F3L 2011 Engine High idle should be 2500 rpm. 3 - 24 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 49: Test The Engine Idle Select

    Result: The engine should change to high idle. 7 Move the engine idle control switch to foot switch activated low idle (turtle symbol). Result: The engine should change to low idle. Part No. 102521 Genie S-40 and Genie S-45 3 - 25...

  • Page 50: Test The Drive Brakes

    6 Measure the distance between the test line and your machine reference point. Refer to Section 2, Specifications. The brakes must be able to hold the machine on any slope it is able to climb. 3 - 26 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 51: Test The Drive Speed - Stowed Position

    Refer to Section 2, Specifications. line. Refer to Section 2, Specifications. 8 Lower the boom to the stowed position and extend the boom 1 foot / 30 cm. Part No. 102521 Genie S-40 and Genie S-45 3 - 27...

  • Page 52: Perform Hydraulic Oil Analysis

    Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil. 3 - 28 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 53: Replace Hydraulic Filters

    6 Push the filter element down to be sure the o-ring on the element is fully seated into the housing. Part No. 102521 Genie S-40 and Genie S-45 3 - 29...

  • Page 54: Replace The Fuel Filter/Water Separator Element - Perkins Models

    Tighten the clamp. 11 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing. 3 - 30 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 55 Tighten the vent plug. 15 Clean up any fuel that may have spilled during this procedure. Part No. 102521 Genie S-40 and Genie S-45 3 - 31...

  • Page 56: Test The Alarm Package (If Equipped)

    3 Turn the key switch to platform controls. Result: The flashing beacons should be and flashing. 4 Move the lift/drive selector switch to the lift position (if equipped). 3 - 32 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 57: Perform Engine Maintenance - Deutz Models

    Crushing hazard. Failure to secure the engine pivot plate from moving the engine pivot plate from moving could result in death or serious could result in death or serious injury. injury. Part No. 102521 Genie S-40 and Genie S-45 3 - 33...

  • Page 58: Perform Engine Maintenance - Perkins Models

    Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 3 - 34 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 59: Checklist C Procedures

    Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. Part No. 102521 Genie S-40 and Genie S-45 3 - 35...
  • Page 60 See D-7, Calibrate the Platform Overload System (if equipped) . There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. 3 - 36 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 61 10 Test all machine functions from the ground controls. Result: All ground control functions should not operate. Machine functions should still operate with auxiliary power at the ground controls. Part No. 102521 Genie S-40 and Genie S-45 3 - 37...

  • Page 62: Perform Engine Maintenance - Perkins Models

    Crushing hazard. Failure to secure the engine pivot plate from moving the engine pivot plate from moving could result in death or serious could result in death or serious injury. injury. 3 - 38 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 63: Checklist D Procedures

    Wear pad specifications All wear pads inch 14.3 mm Part No. 102521 Genie S-40 and Genie S-45 3 - 39...
  • Page 64 8 Remove drive chassis covers from both the the fasteners into the engine tray steer end and the non-steer end of the machine. to secure it from moving could result in death or serious injury. 3 - 40 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 65: Check The Free-Wheel Configuration

    4 Disengage the drive hubs by turning over the engaged position drive hub disconnect caps on each non-steer wheel hub. disengaged position engaged position Part No. 102521 Genie S-40 and Genie S-45 3 - 41...

  • Page 66: Replace The Drive Hub Oil

    Install the plugs into the drive hub. 5 Repeat steps 1 through 4 for all the other drive hubs. 3 - 42 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 67: Check And Adjust The Air/Lpg Mixture - Ford Models

    3 Loosen the lock nut on the high idle mixture adjustment screw. 4 Load the system by activating the primary boom retract function, then move the function enable toggle switch to the high idle (rabbit symbol) position. Part No. 102521 Genie S-40 and Genie S-45 3 - 43...

  • Page 68: Perform Engine Maintenance - Deutz Models

    Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 3 - 44 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 69 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. If the platform overload system is not operating properly, repeat steps 1 through 4. Part No. 102521 Genie S-40 and Genie S-45 3 - 45...

  • Page 70: Replace The Hydraulic Filters

    6 Push the filter element down to be sure the o-ring on the element is fully seated into the housing. 7 Rotate the filter element clockwise to lock it in place. 3 - 46 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 71: Checklist E Procedures

    The hoses can be accessed through the access hole under the turntable. 8 Disconnect and plug the return filter hydraulic hose at the return filter. Cap the fitting on the filter housing. Part No. 102521 Genie S-40 and Genie S-45 3 - 47...
  • Page 72 19 Install the hydraulic tank onto the machine. 20 Install the two suction hoses to the suction strainers. 21 Install the supply hose for the auxiliary power unit and the return filter hose. 3 - 48 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 73: Perform Engine Maintenance - Deutz Models

    Crushing hazard. Failure to secure the engine pivot plate from moving the engine pivot plate from moving could result in death or serious could result in death or serious injury. injury. Part No. 102521 Genie S-40 and Genie S-45 3 - 49...
  • Page 74 Section 3 • Scheduled Maintenance Procedures January 2005 This page intentionally left blank. 3 - 50 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 75 Read, understand and obey the safety rules which, if not avoided, will result in and operating instructions in the Genie S-40 death or serious injury. and Genie S-45 Operator’s Manual. Used to indicate the presence of a...

  • Page 76: Platform Controls

    Remove all rings, watches and other jewelry. ALC-500 circuit board drive/steer joystick controller secondary boom up/down joystick controller primary boom up/down and turntable rotate left/right joystick controller 4 - 2 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 77: Joysticks

    6 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. No machine fuction should operate while performing the joystick calibration procedure. Part No. 102521 Genie S-40 and Genie S-45 4 - 3...
  • Page 78 4 times. Result: There should be a pause and the alarm should sound 4 times indicating that the machine is in max-out calibration mode. 4 - 4 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 79 0.5 second decelerate, coasting 0.75 second decelerate, braking 1 second decelerate, shift from low to high speed 1 second decelerate, shift from high to low speed 4 seconds Part No. 102521 Genie S-40 and Genie S-45 4 - 5...
  • Page 80 Section 4 • Repair Procedures January 2005 PLATFORM CONTROLS REV A This page intentionally left blank. 4 - 6 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 81: Platform Components

    1 Raise the primary boom to a horizontal position. 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system. Part No. 102521 Genie S-40 and Genie S-45 4 - 7...

  • Page 82: Platform Rotator

    Fitting Torque Specifications. properly supported. 1 Remove the platform and platform support. 6 Support the platform rotator with an appropriate lifting device. Do not apply any lifting pressure. 4 - 8 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 83 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform fully in both directions and inspect the bleed valves for leaks. Part No. 102521 Genie S-40 and Genie S-45 4 - 9...

  • Page 84: Jib Boom Components

    6 Remove the hose cover, hoses and cables from the side of the jib boom and set them aside. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 4 - 10 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 85: Jib Boom Lift Cylinder

    Loosen hydraulic connections very slowly to allow machine if not properly attached to the overhead crane. the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 102521 Genie S-40 and Genie S-45 4 - 11...

  • Page 86: Boom Components

    11 Remove the fasteners from the drive speed limit platform support. switch mounted on the side of the cable track at the pivot end of the boom. Do not disconnect the wiring. 4 - 12 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 87 8 Operate the boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track. Part No. 102521 Genie S-40 and Genie S-45 4 - 13...

  • Page 88: Boom

    How to Remove the Boom the overhead crane. Component damage hazard. Consult the Genie Industries Service Department When lowering the master cylinder for instructions on how to safely remove the boom down, be sure not to damage the assembly from the machine.

  • Page 89: Boom Lift Cylinder

    4 Support and secure both ends of the boom lift cylinder will clear the mounting bracket on the cylinder to a second overhead crane or similar boom. Turn the machine off. lifting device. Part No. 102521 Genie S-40 and Genie S-45 4 - 15...
  • Page 90 Note the length of the cylinder after removal. The cylinder must be at the same length for installation. 4 - 16 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 91: Platform Leveling Master Cylinder

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 102521 Genie S-40 and Genie S-45 4 - 17...

  • Page 92: Rpm Adjustment - Deutz Models

    Do not lift it. 0.18 inch / 4.6 mm gap - Diesel Models 0.060 inch / 1.5 mm gap - Ford Models 4 - 18 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 93 Component damage hazard. Hoses can be damaged if they are kinked or pinched. 6 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. Part No. 102521 Genie S-40 and Genie S-45 4 - 19...

  • Page 94: Engine Fault Codes - Ford Models

    That would indicate code to retrieve fault codes stored within the ECM. 531. There will be a longer pause Contact Genie Industries Service Department for between codes. assistance in retrieving fault codes. 6 Refer to Section 5, Fault Codes , for definition of engine fault codes.

  • Page 95: Hydraulic Pumps

    If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Part No. 102521 Genie S-40 and Genie S-45 4 - 21...

  • Page 96: Drive Pump

    Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center. Call Genie Industries Service Department to locate your local authorized service open closed center.
  • Page 97 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the 7 Start the engine from the ground controls and machine. check for hydraulic leaks. Part No. 102521 Genie S-40 and Genie S-45 4 - 23...

  • Page 98: Function Manifold Components

    (S-45) ......... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 0.6 gpm / 2.27 L/min ......AA ..platform rotate (S-40) ......20-25 ft-lbs / 27-34 Nm Check valve ........AB ..Differential sensing circuit, platform rotate right and jib boom down (S-45) ......
  • Page 99 January 2005 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102521 Genie S-40 and Genie S-45 4 - 25...
  • Page 100 2900 psi / 200 bar ......AQ ..System relief (S-45) ......30-35 ft-lbs / 41-47 Nm Relief valve, 2600 psi / 179 bar ......AQ ..System relief (S-40) ......30-35 ft-lbs / 41-47 Nm Flow regulator valve, 4.5 gpm / 17.03 L/min ......AR ..Bleeds off differential sensing valves to tank ........
  • Page 101 January 2005 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102521 Genie S-40 and Genie S-45 4 - 27...

  • Page 102: Valve Adjustments - Function Manifold

    Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 4 - 28 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 103: Jib Select And Platform Rotate Manifold Components

    Counterbalance valve ......CB ..Platform rotate left ......30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ..CC ..Platform rotate/jib boom select ..18-20 ft-lbs / 25-27 Nm Jib Select Manifold Platform Rotate Manifold Part No. 102521 Genie S-40 and Genie S-45 4 - 29...

  • Page 104: Brake Manifold Components (Before Serial No. 7569)

    Solenoid valve, 2 position 3 way ..DA ... Brake release ........20-25 ft-lbs / 27-34 Nm Orifice, 0.025 inch / 0.635 mm ..DB ... Turntable rotation brake release 4 - 30 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 105: Brake/Two-Speed Manifold Components (After Serial No. 7568)

    Solenoid valve, 2 position 3 way ..EC ... Two-speed motor shift ..... 20-25 ft-lbs / 27-34 Nm Check valve ........ED ... Brake release circuit ......20-25 ft-lbs / 27-34 Nm Part No. 102521 Genie S-40 and Genie S-45 4 - 31...
  • Page 106 The oscillate directional valve is mounted inside the drive chassis at the non-steer end. Index Description Function Torque Cap ..............Breather ..........20-25 ft-lbs / 27-33 Nm Spool valve ............Directional control Relief valve ............Pressure adjustment 4 - 32 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 107 Check to be sure the drive chassis is completely level. 6 To level the drive chassis, start the engine and loosen the lock nuts on both sides of the urethane cushions. Part No. 102521 Genie S-40 and Genie S-45 4 - 33...

  • Page 108: Valve Adjustments, Oscillate Relief Valve

    Oscillate relief valve specification Pressure 950 psi 65.5 bar 6 Turn the engine off. 7 Locate the relief valve on the directional valve and remove the cap. 4 - 34 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 109: Traction Manifold Components, 2Wd (Before Serial No. 7569)

    (item FB) Shuttle valve, 3 position 3 way ..FD ..Charge pressure, hot oil shuttle ..50-55 ft-lbs / 68-75 Nm Diagnostic nipple ....... FE ..Testing Part No. 102521 Genie S-40 and Genie S-45 4 - 35...

  • Page 110: Traction Manifold Components, 2Wd (After Serial No. 7568)

    Flow divider/combiner valve ....GE ..Controls flow to drive motors in forward and reverse ...... 50-55 ft-lbs / 68-75 Nm Orifice, 0.070 inch / 1.78 mm .... GF ..Equalizes flow across flow divider/combiner valve (item GB) 4 - 36 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 111 3 Turn the engine off and connect a 0 to 600 psi / 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold. Part No. 102521 Genie S-40 and Genie S-45 4 - 37...

  • Page 112: Traction Manifold Components, 4Wd (Before Serial No. 7569)

    Relief valve, 210 psi / 14.5 bar ..HH ..Charge pressure circuit ..... 30-35 ft-lbs / 41-47 Nm Orifice, 0.052 inch / 1.32 mm .... HI ..Front drive motor circuit 4 - 38 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 113 January 2005 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102521 Genie S-40 and Genie S-45 4 - 39...

  • Page 114: Traction Manifold Components, 4Wd (After Serial No. 7568)

    Flow divider/combiner valve ....JM ..Controls flow to steer end drive motors in forward and reverse ........80-90 ft-lbs / 108-122 Nm Check valve ........JN ..Non-steer end drive motor circuit ..35-40 ft-lbs / 48-54 Nm 4 - 40 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 115 January 2005 Section 4 • Repair Procedures REV A MANIFOLDS Part No. 102521 Genie S-40 and Genie S-45 4 - 41...
  • Page 116 3 Turn the engine off and connect a 0 to 600 psi / 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold. 4 - 42 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 117: Valve Coils

    MANIFOLDS 7-14 How to Test a Coil Diode Valve Coils Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional How to Test a Coil valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit A properly functioning coil provides an by suppressing voltage spikes.
  • Page 118 9V DC battery 10Ω resistor coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6 4 - 44 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 119: Turntable Rotation Components

    1 Secure the turntable from rotating with the turntable rotation lock pin. brake assembly drive hub Unlocked position backlash plate mounting bolts backlash plate manifold motor Locked position Part No. 102521 Genie S-40 and Genie S-45 4 - 45...
  • Page 120 When installing the drive hub assembly: 6 Install the drive hub. Torque the backlash plate mounting bolts to 260 ft-lbs / 352.5 Nm. 4 - 46 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 121: Axle Components

    Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Rotate the turntable until the boom is between the steer tires. Part No. 102521 Genie S-40 and Genie S-45 4 - 47...
  • Page 122 Section 4 • Repair Procedures January 2005 REV A This page intentionally left blank. 4 - 48 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 123 Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-40 and Genie S-45 Operator’s Manual. Be sure that all necessary tools and test Observe and Obey: equipment are available and ready for use.

  • Page 124: Fault Codes - Control System

    OR use a grounded wrist strap. 5 - 2 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 125 (transient) Boom 2 directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Continued on next page Part No. 102521 Genie S-40 and Genie S-45 5 - 3...
  • Page 126 Self-clearing. Just calibrated is zero. (transient) Drive enable Enable override Power up override switches Fault direction is frozen at controller with neutral. problem corrected. 5 - 4 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 127 Self-clearing. Just calibrated of alarm. (transient) Steer directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Part No. 102521 Genie S-40 and Genie S-45 5 - 5...

  • Page 128: Fault Codes - Ford Engine

    Check Engine Light. Refer to Repair Procedure 5-4, How to Retrieve Engine Fault Codes. Use the Fault Code Chart on the following pages to aid in identifying the fault. 5 - 6 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 129 Repair wiring and/or connections OR replace IAT Low Voltage shorted OR sensor is faulty OR engine intake air sensor OR direct cooler air into air intake. temperature is too hot. Continued on next page Part No. 102521 Genie S-40 and Genie S-45 5 - 7...
  • Page 130 Repair wiring and/or connections to fuel Injector Driver #2 Shorted shorted OR fuel injector #2 is faulty OR ECM is injector #2 OR replace fuel injector #2 OR faulty. replace the ECM. 5 - 8 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 131 Wiring and/or connections to ignition coil #2 Repair wiring and/or connections to ignition Coil Driver #2 Shorted shorted OR ignition coil #2 is faulty. coil #2 OR replace ignition coil #2. Continued on next page Part No. 102521 Genie S-40 and Genie S-45 5 - 9...
  • Page 132 Locate and repair any engine harness wiring Loose wire connections to ECM OR ECM is A/D Loss damage or shorts to ECM to be sure they are faulty. secure OR replace ECM. 5 - 10 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 133 Locate and repair any engine harness wiring Loose wire connections to ECM OR ECM is RTI 3 Loss damage or shorts to ECM to be sure they are faulty.S secure OR replace ECM. Part No. 102521 Genie S-40 and Genie S-45 5 - 11...
  • Page 134 Section 5 • Fault Codes January 2005 REV A This page intentionally left blank. 5 - 12 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 135 Read, understand and obey the safety rules or spray. and operating instructions printed in the Genie S-60 & Genie S-65 Operator's Manual. General Repair Process Be sure that all necessary tools and test equipment are available and ready for use.

  • Page 136: Electrical Symbols Legend

    Toggle switch DPDT Fuse with amperage Key switch N.O. Circuit breaker with amperage Fuel or RPM Control relay contact solenoid normally open Starting aid: glow plug or flame ignitor Coil 6 - 2 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 137 2 position, 2 way solenoid valve Pump prime mover (engine or motor) Differential sensing valve Directional valve pilot operated 2 position, 2 way Double acting cylinder Solenoid operated proportional valve Part No. 102521 Genie S-40 and Genie S-45 6 - 3...
  • Page 138 Section 6 • Schematics January 2005...

  • Page 140: Electrical Schematic, Deutz F3L 1011 Models (Before Serial No. 7544)

    PUMP REGULATOR IND. NOTE: 1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. 6 - 4 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 141 TB40 TB13 TB37 TB30 TB17 TB15 TB18 TB14 TB22 C6-30 SJ1-WH NOHC NOHC NONC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 Genie S-40 and Genie S-45 6 - 5...
  • Page 142 January 2005 Section 6 • Schematics Electrical Schematic Deutz F3L 1011F Models (before serial no. 7544)

  • Page 143: Ground Control Box Wiring Diagram

    BK-ISM#1 RD- 24A RD- 20B RD- P1 E-STOP BK-C5-5 WH-21B OR-C6-33 OR/BK-15A BK-C6-16 BR-GND+C6-26 OR-14A BK/RD-35B GR-17A GR/WH-19A GR/BK-18A BK/RD-C5-9 WIRING GROUND STUD HARNESS: TO BASE ALL BR WIRES Part No. 102521 Genie S-40 and Genie S-45 6 - 6...

  • Page 144: Deutz F3L 1011 Models (Before Serial No. 7544)

    January 2005 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz F3L-1011 Models (before serial no. 7544)

  • Page 145: Platform Control Box Wiring Diagram

    Section 6 • Schematics January 2005 Platform Control Box Wiring Diagram Deutz F3L-1011 Models (before serial no. 7544)
  • Page 146 PART NUMBER TILT ALARM 45383 ALC-500 89353 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GN/BK C4P-4 BATGND C7P-3 F.S. LS18 OPT. TILT ALALRM 19/18 CONTROL CABLE 12V BATT F.S. 6 - 7 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 147 HIGH/LOW GLOW PLUG START GR/BK HORN AUXILIARY PUMP PLATFORM EMERGENCY STOP REMOVE FOR GENERATOR OPTION LEVEL PLATFORM ROTATE CE SEE DETAIL A NOTE: 1) DASHED LINES INDICATE OPTION WIRES. Part No. 102521 Genie S-40 and Genie S-45 6 - 8...
  • Page 148 January 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Deutz F3L-1011 Models (before serial no. 7544)

  • Page 150: Electrical Schematic Perkins 704-30 Models (Before Serial No. 7472)

    PUMP REGULATOR IND. NOTE: 1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. 6 - 9 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 151: Perkins 704-30 Models (Before Serial No. 7472)

    TB36 TB40 TB30 TB32 TB15 TB17 TB18 TB14 C6-30 SJ1-WH TB22 NOHC NONC NOHC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 Genie S-40 and Genie S-45 6 - 10...

  • Page 152: Perkins 704-30 Models (Before Serial No. 7472)

    January 2005 Section 6 • Schematics Electrical Schematic Perkins 704-30 Models (before serial no. 7472)
  • Page 153 PLAT OVERLOAD MODULE RD- P1 E-STOP BK-C5-5 WH-21B OR-C6-33 PLAT OVERLOAD LED OR/BK-15A BK-C6-16 BR-GND+C6-26 OR-14A BK/RD-35B GR-17A GR/WH-19A GR/BK-18A BK/RD-C5-9 WIRING GROUND STUD HARNESS: TO BASE ALL BR WIRES Part No. 102521 Genie S-40 and Genie S-45 6 - 11...
  • Page 154 January 2005 Section 6 • Schematics Ground Control Box Wiring Diagram Perkins 704-30 Models (before serial no. 7472)
  • Page 155 Section 6 • Schematics January 2005 Platform Control Box Wiring Diagram Perkins 704-30 Models (before serial no. 7472)
  • Page 156 PART NUMBER TILT ALARM 45383 ALC-500 89353 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GN/BK C4P-4 BATGND C7P-3 F.S. LS18 OPT. TILT ALALRM 19/18 CONTROL CABLE 12V BATT F.S. 6 - 12 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 157 GLOW PLUG HIGH/LOW START GR/BK HORN PLATFORM AUXILIARY PUMP EMERGENCY STOP REMOVE FOR GENERATOR OPTION LEVEL PLATFORM ROTATE CE SEE DETAIL A NOTE: 1) DASHED LINES INDICATE OPTION WIRES. Part No. 102521 Genie S-40 and Genie S-45 6 - 13...
  • Page 158 January 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Perkins 704-30 Models (before serial no. 7472)

  • Page 160: Electrical Schematic Ford Lrg-425 Efi Models (Before Serial No. 7597)

    FORD ENGINE HARNESS NOTE: 1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. 6 - 14 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 161: Ford Lrg-425 Efi Models (Before Serial No. 7597)

    TB40 TB13 TB30 TB31 TB17 TB15 TB18 TB14 TB22 C6-30 SJ1-WH NOHC NOHC NONC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 Genie S-40 and Genie S-45 6 - 15...

  • Page 162: Ford Lrg-425 Efi Models (Before Serial No. 7597)

    January 2005 Section 6 • Schematics Electrical Schematic Ford LRG-425 EFI Models (before serial no. 7597)
  • Page 163 RD- P1 E-STOP WH-ISM#7 HOUR METER BR-R1 WH-23B OR/BK-15A BR-GND BLK-33B OR-14A BK/RD-C5-12 WH CR2#87 WH-C5-17 GR-17A TS22 GR/WH-19A GR/BK-18A WIRING HARNESS: TO BASE GROUND STUD ALL BR WIRES Part No. 102521 Genie S-40 and Genie S-45 6 - 16...
  • Page 164 January 2005 Section 6 • Schematics Ground Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial no. 7597)
  • Page 165 Section 6 • Schematics January 2005 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial no. 7597)
  • Page 166 PART NUMBER TILT ALARM 45383 ALC-500 89353 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GR/BK C4P-4 BATGND C7P-3 F.S. LS18 OPT. TILT 19/18 CONTROL CABLE 12V BATT F.S. ALALRM 6 - 17 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 167 NOTE: TS47 START FUEL SELECT DASHED LINES INDICATE HORN AUXILIARY GENERATOR PLATFORM EMERGENCY STOP OPTION WIRES PUMP (OPTION) LEVEL PLATFORM CE SEE DETAIL A ROTATE REMOVE FOR GENERATOR OPTION Part No. 102521 Genie S-40 and Genie S-45 6 - 18...
  • Page 168 January 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (before serial no. 7597)

  • Page 169: (Before Serial No. 7569)

    RELEASE RIGHT 185 psi OPTIONAL 12.7 bar TO HYD ROTARY COUPLER GENERATOR RIGHT LEFT STEERING 210 psi 14.5 bar .070 REAR 185 psi 12.7 bar LEFT RELEASE TRACTION MANIFOLD Part No. 102521 Genie S-40 and Genie S-45 6 - 19...
  • Page 170 January 2005 Section 6 • Schematics 2WD Non-Oscillating Hydraulic Schematic S-40 Models (before serial no. 7569)

  • Page 171: (Before Serial No. 7569)

    TEST 3500 PSI REAR RIGHT 185 psi 12.7 bar OPTIONAL TO HYD ROTARY COUPLER RELEASE GENERATOR RIGHT STEERING LEFT .070 REAR 185 psi LEFT 12.7 bar RELEASE TRACTION MANIFOLD Part No. 102521 Genie S-40 and Genie S-45 6 - 20...
  • Page 172 January 2005 Section 6 • Schematics 2WD Non-Oscillating Hydraulic Schematic S-45 Models (before serial no. 7569)
  • Page 173 TO HYD ROTARY COUPLER GENERATOR RIGHT STEERING LEFT 210 psi 14.5 bar TEST .070 .052 .070 950 psi REAR 65.5 bar LEFT RIGHT RIGHT FRONT RIGHT OSCILLATE VALVE TRACTION MANIFOLD OSCILLATE CYLINDERS Part No. 102521 Genie S-40 and Genie S-45 6 - 21...
  • Page 174 January 2005 Section 6 • Schematics 4WD Oscillating Hydraulic Schematic S-40 Models (before serial no. 7569)
  • Page 175 PUMP 14.5 bar TEST .070 .052 .070 OPTIONAL GENERATOR TO HYD ROTARY COUPLER 950 psi REAR 65.5 bar LEFT RIGHT RIGHT FRONT RIGHT OSCILLATE VALVE TRACTION MANIFOLD OSCILLATE CYLINDERS Part No. 102521 Genie S-40 and Genie S-45 6 - 22...
  • Page 176 January 2005 Section 6 • Schematics 4WD Oscillating Hydraulic Schematic S-45 Models (before serial no. 7569)

  • Page 178: Electrical Schematic Deutz F3L-2011 Models (After Serial No. 7543)

    IND. NOTE: 1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. C.E. OPTION ONLY 6 - 23 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 179: Deutz F3L 2011 Models (After Serial No. 7543)

    SJ1-WH TB22 C6-30 Y17 Y16 Y19 Y20 Y21 Y22 Y29 Y23 NOHC NCHO NOHC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 Genie S-40 and Genie S-45 6 - 24...

  • Page 180: Deutz F3L 2011 Models (After Serial No. 7543)

    January 2005 Section 6 • Schematics Electrical Schematic Deutz F3L-2011 Models (after serial no. 7543)
  • Page 181 WH-21B RD- 20B BK/RD-C5-9 RD- P1 E-STOP OR/BK-15A BK-C6-16 OR-C6-33 OR-14A GR-17A GR/WH-19A GR/BK-18A GR-43D CR17 BK-C6-25 BK-22B RD-CB3 SP WIRING GROUND STUD HARNESS: TO BASE ALL BR WIRES Part No. 102521 Genie S-40 and Genie S-45 6 - 25...
  • Page 182 January 2005 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz F3L-2011 Models (after serial no. 7543)
  • Page 183 Section 6 • Schematics January 2005 Platform Control Box Wiring Diagram Deutz F3L-2011 Models (after serial no. 7543)
  • Page 184 COMPONENT INDEX PART NUMBER TILT ALARM 45383 ALC-500 94771 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GR/BK C4P-4 BATGND C7P-3 LS18 OPT. TILT 12V BATT ALALRM 19/18 CONTROL CABLE F.S. 6 - 26 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 185 (OPTION) EMERGENCY STOP NOTE: 1) DASHED LINES INDICATE OPTION WIRES. TS14 PLATFORM HIGH/LOW GLOW PLUG HIGH/LOW HORN ROTATE PLATFORM AUXILIARY PUMP DRIVE GR/BK LEVEL SPEED CE SEE DETAIL A Part No. 102521 Genie S-40 and Genie S-45 6 - 27...
  • Page 186 January 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Deutz F3L-2011 Models (after serial no. 7543)

  • Page 188: Electrical Schematic Perkins 404-22 Models (After Serial No. 7471)

    IND. NOTE: 1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. C.E. OPTION ONLY 6 - 28 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 189: Perkins 404-22 Models (After Serial No. 7471)

    SJ1-WH TB22 C6-30 Y17 Y16 Y19 Y20 Y21 Y22 Y29 Y23 NOHC NCHO NOHC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 Genie S-40 and Genie S-45 6 - 29...

  • Page 190: Perkins 404-22 Models (After Serial No. 7471)

    January 2005 Section 6 • Schematics Electrical Schematic Perkins 404-22 Models (after serial no. 7471)
  • Page 191 WH-21B RD- 20B BK/RD-C5-9 RD- P1 E-STOP OR/BK-15A BK-C6-16 OR-C6-33 OR-14A GR-17A GR/WH-19A GR/BK-18A GR-43D CR17 BK-C6-25 BK-22B RD-CB3 SP GROUND STUD WIRING HARNESS: TO BASE ALL BR WIRES Part No. 102521 Genie S-40 and Genie S-45 6 - 30...
  • Page 192 January 2005 Section 6 • Schematics Ground Control Box Wiring Diagram Perkins 404-22 Models (after serial no. 7471)
  • Page 193 Section 6 • Schematics January 2005 Platform Control Box Wiring Diagram Perkins 404-22 Models (after serial no. 7471)
  • Page 194 COMPONENT INDEX PART NUMBER TILT ALARM 45383 ALC-500 94771 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GR/BK C4P-4 BATGND C7P-3 OPT. LS18 TILT ALALRM 19/18 CONTROL CABLE 12V BATT F.S. 6 - 31 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 195 (OPTION) EMERGENCY STOP NOTE: 1) DASHED LINES INDICATE OPTION WIRES. TS14 PLATFORM HIGH/LOW GLOW PLUG HIGH/LOW HORN PLATFORM ROTATE AUXILIARY PUMP DRIVE GR/BK LEVEL SPEED CE SEE DETAIL A Part No. 102521 Genie S-40 and Genie S-45 6 - 32...
  • Page 196 January 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Perkins 404-22 Models (after serial no. 7471)

  • Page 198: Electrical Schematic Ford Lrg-425 Efi Models (After Serial No. 7596)

    ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. REFER TO E0375 FOR FORD HARNSS 6 - 33 Genie S-40 and Genie S-45 Part No. 102521...

  • Page 199: Ford Lrg-425 Efi Models (After Serial No. 7596)

    TB30 TB29 TB15 TB40 TB13 TB14 TB17 TB18 SJ1-WH TB22 C6-30 NCHO NOHC NOHC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 Genie S-40 and Genie S-45 6 - 34...

  • Page 200: Ford Lrg-425 Efi Models (After Serial No. 7596)

    January 2005 Section 6 • Schematics Electrical Schematic Ford LRG-425 EFI Models (after serial no. 7596)
  • Page 201 RD- P1 E-STOP HOUR METER RD-27B CR39 CR17 OR/BK-15A GR-43B BK-C6-25 BK-22B OR-14A RD-CB3 SP GR-C5-12 GR-17A WH-23B GR/WH-19A GR/BK-18A WIRING HARNESS: TO BASE GROUND STUD ALL BR WIRES Part No. 102521 Genie S-40 and Genie S-45 6 - 35...
  • Page 202 January 2005 Section 6 • Schematics Ground Control Box Wiring Diagram Ford LRG-425 EFI Models (after serial no. 7596)
  • Page 203 Section 6 • Schematics January 2005 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (after serial no. 7596)
  • Page 204 COMPONENT INDEX PART NUMBER TILT ALARM 45383 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GR/BK C4P-4 BATGND C7P-3 F.S. LS18 OPT. TILT 19/18 CONTROL CABLE 12V BATT F.S. ALALRM 6 - 36 Genie S-40 and Genie S-45 Part No. 102521...
  • Page 205 START FUEL SELECT DASHED LINES INDICATE HORN AUXILIARY GENERATOR PLATFORM SPEED EMERGENCY STOP OPTION WIRES PUMP (OPTION) LEVEL HIGH/LOW PLATFORM CE SEE DETAIL A ROTATE REMOVE FOR GENERATOR OPTION Part No. 102521 Genie S-40 and Genie S-45 6 - 37...
  • Page 206 January 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (after serial no. 7596)
  • Page 207 GENERATOR TO HYD ROTARY COUPLER STEERING TEST 280 psi .070 19.3 bar 950 psi 65.5 bar LEFT RIGHT TRACTION OSCILLATE VALVE MANIFOLD LEFT REAR OSCILLATE CYLINDERS OPTION OSCILLATE CYLINDERS Part No. 102521 Genie S-40 and Genie S-45 6 - 38...
  • Page 208 January 2005 Section 6 • Schematics 2WD Hydraulic Schematic (after serial no. 7568)
  • Page 209 .040 19.3 bar 950 psi .040 65.5 bar LEFT RIGHT OPTIONAL GENERATOR TO HYD ROTARY COUPLER TRACTION OSCILLATE VALVE MANIFOLD LEFT LEFT FRONT REAR OSCILLATE CYLINDERS OPTION OSCILLATE CYLINDERS Part No. 102521 Genie S-40 and Genie S-45 6 - 39...
  • Page 210 January 2005 Section 6 • Schematics 4WD Hydraulic Schematic- (after serial no. 7568)
  • Page 211 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie China Genie Scandinavia Phone +86 21 53852570...

This manual is also suitable for:

S-45

Table of Contents

Save PDF